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Old 23 Mar 2014
suhasrocky's Avatar
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New Exhaust System for bikes

Hello folks!

It's been quite a while since i've posted in the forums. Now, I want your help with something.

I've been studying masters Aerospace Engineering at Technical University of Delft, Netherlads, for the past year. Apart from studying about aircrafts, I also work with the University's bike racing team 'Novabike" and as part of the team, I have designed the exhaust system for the bike of this year.

Biking and travelling have gone hand in hand for me. I have noticed that bikes have got sleeker, better, and more and more technical, the exhaust system has just been left behind. I mean, there's nothing radical in terms of improvement, nor utilizing new technology. Granted, Akrapovic, probably the largest manufacturer for custom exhausts has some tricks up to its sleeve, and has titanium exhaust systems, with carbon fibre outer cover for aesthetic reasons. But that's that.

I believe aftermarket exhausts are probably the most visible component on the bike that define its uniqueness, why has design and technology remained pretty much the same?

Surely, there is so much more that can be done in this direction, and I've been working on a new exhaust system for motorcycles as part of a project for my Masters. This is partly because i've the technical knowledge to desgn an exhaust, and partly because I want to do something to give back to the motorcycling world. Part of the project is to get a projection of what type aftermarket exhaust systems are used by bikers and what define these people. As a result, i've made a survey. Can you please help me by filling it up? I will not take more than 2 minutes of your time.

Why should you fill up the form? Well, while it would be of invaluable help to me, I would also like to mention here that people who have filled up the form and want more information about what the project on exhaust systems is all about can always contact me, here, on the forum, or by email. But more importantly, If you are interested, you'll get to be involved in the project, as to how the exhaust should look, or sound, what can be done to the end product that would make a biker want to buy it and put it on his bike.

I'll do the technical work here at Delft University. Your input will be more on the design and how you feel the exhaust should go with the bike, so we can work together with our designer to get the product design right.

Here's the link: https://docs.google.com/forms/d/1hij...kqDPI/viewform

If you want more information, you can contact me after filling in the form.


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Old 23 Mar 2014
mollydog's Avatar
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I hope your research and study include looking at recent history in gas flow and induction technology in modern motorcycles. The Japanese have made an art form of these areas and have made HUGE strides in performance while being able to meet ever more stringent noise, weight and space limitations.

How do they do that?

An integral part of any exhaust system is intake flow and efficiency. Air box design is HUGE and the Japanese (and Italians) have made huge inroads using very advanced computers to analyze and design air boxes and direct air flow to max out power, yet be quiet. (not so easy)

In terms of materials ... it's not just Akrapovic using Titanium. Japanese sport bikes have used Titanium in their exhaust since the mid 2000's ... stock, from the factory. Where have you been? In fact, I bought a used 2005 GSXR 1000 Titanium exhaust can to adapt to my DR650 single. It's a perfect fit.

I hope in your research you look at the elaborate 3 chamber exhaust designs the Japanese have created ... keeping things quiet but still allowing tremendous power ... and power that goes UP and UP every year.

How do they manage that?

Answer: they've been hard at it since the early
1980's or before. 30 plus years of very expensive research has brought many improvements. The Japanese way is slow evolution ... never revolution.

Look into it ... I think you may be surprised to know just how much work goes into both intake and exhaust systems done by the OEM's. I wish you luck in your endeavor! Maybe you can design something better than the thousands of engineers who've been doing it for the last 30 years!

I'd recommend going to Japan and taking a factory tour. Ask to see the R&D facilities. I visited Yamaha in mid 90's. Very educational for sure. Then have a very close read of the latest Euro lll and lV rules regards exhaust and intake noise. Here in the USA we are likely to soon have exhaust checks every other year. Any NON STANDARD exhaust is now illegal ... but not enforced. This is all changing. The Japanese are ready to meet this challenge.
Is Akrapovic?
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Old 28 Mar 2014
suhasrocky's Avatar
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Hey mollydog,

To answer some of your questions, right now, the main goal is to make the muffler first, and road test it to get performance rating and reliability in real world conditions. of course, this will all be done after dyno tests.

And yes, I do know that titanium has been in use as a stock material on factory bikes for some time now. I assume this thought of yours is due to the question of what material is the exhaust made of. In general, I just wanted to get an idea of what kind of aftermarket exhaust systems do people use, and hence the question.

I like the way you put this: "The Japanese way is slow evolution, never revolution"... very catchy, and apt.

Hopefully, we can do something that is just that much better than all the OEMS and manufacturers are doing. Thanks!

Going to Japan and taking a factory tour is not an option right now, but maybe sometime, we may get invited to do so


And for the people new to the post, here's the link for a quick survey which will take less then 2 minutes of your time, but help me a lot.

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